Conversion of hydrocarbons



Oct. 16, 1945. M PUMA'ruszAK. v 2,33762 CONVERSION 0F HYDROGARBONS Filed Dec. 4, 1942 ATTORNEYS Patented Oct. 16, 1.945-

iJNlTEo STATES PATE CONVERSION F HYDBOCARBONS Max-yan P. Matuszak, Bartlesville, Okla., assigner to Phillips Petroleum Company, a corporation oi.' Delaware 4 Claims.

This invention relates to a process for the conversion of hydrocarbons in the presence of a liquid acid-type catalyst. This application is a continuation-impart of my copending application, Serial No. 395,282, filed May 26, 1941, now

Patent 2,320,629, issued June 1, 1943.

In present-day acid-catalyzed hydrocarbon alkylation processes, it is necessary, for obtaining optimum results, to limit the proportions of inert diluents in the feeds to the alkylating zones. Diluents in the feeds reduce the maximum production capacities of alkylating equipment and, if present in very high proportions, cause reductions in yield and quality of products. Diluents are sometimes removed from feeds by fractional distillation: however, in many instances, particularly in the utilization of olefinic streams which contain only a few per cent of olen, fractional distillation to remove diluents is not economically practicable.

In present-day acid-catalyzed alkylation processes for reacting paraillns with olens to produce heavier paraflins, the principal or maior constituents of the alkylates produced under ordinary good reaction conditions are those which would be formed if one olen molecule added to one paran molecule by a mechanism, herein termed paraffin-olefin juncturawhereby appare ently a methyl group from the original paraiin becomes attached to one of the two double-bond carbon atoms of the original olefin and the rest yoi the original parailln becomes attached to the other double-bond carbon atom of the original olefin. The number of carbon atoms per molecule of the major chemicalcomponents of the product is equal to the sum of the numbers of carbon atoms per molecule of the paraiiln and the olen reactants. Further, only a limited number of the many parailln isomers characterized by this number of carbon atoms per molecule are formed as primary products of simple/parafn-olefin junctures, although other isomers may be formed in small proportions by so-called secondary and side reactions, such as isomerization ofthe primary product, dimerization of the original olein` a'ccompanied or followed by hydrogenation of the dimer, and the like.

Those skilled in the art of alkylation have hitherto directed their efforts mainly towards increasing the extent of the simple parain-olen juncture and towards decreasing the extent of side reactions, especially polymerization of the olefin. However, in many instances, specific side reactions other than polymerization produce constituents in the alkylate that are more desirable than -those produced by the juncture of the initial parafiin with the initial olei'ln. Further, these specific desirable side reactions may be greatly and selectively promoted in accordance with the concept oi the present invention. c

Application December 4, 1942, Serial No. `46"],874-

(Cl. 26o-683.4)

An object of this invention is to provide an im# proved process for conversion of lower boiling hy-l drocarbons to `higher boiling hydrocarbons.

Another object of this invention is to produce parailins by an alkylation process whereinv certain desirable side reactions, which ordinarily occur to only a limited extent, are selectively promoted so that they occur to a much larger extent.

Another object of this invention is to remove inert diluents from olefin-containing feeds to alkya lation processes and simultaneously to convert the olens to simple olefin-catalyst addition products or complexes prior to introducing said oleiins into analkylating zone. y

Another object of this invention is so to react isobutane and a non-isobutylene olefin having three to ve carbon atoms per molecule-as to ob tain high yields of isoctane.

A speciiic object of this invention is to convert propylene, in a hydrocarbonstream containing' inert diluents, to isopropyl fluoride, to extract the resulting isopropyl iiu'oride in liquid concentrated hydroiiuoric acid, andvto utilize the extract as' l alkylating agent and catalyst in an alkylating' in the presence of a liquid acid-type alkylation catalyst. Other objects and advantages of this invention will appear from the following detailed description, taken in conjunction with the accompanying drawing, which is a diagrammatic elevational view of one specific modiilcation of apparatus suitable for use in carrying out' the process of the invention.

.lis catalyst in the process may be used anyl v liquid acid-type catalyst capable of promoting the desired alkylation reaction. Examples of such catalysts are: concentrated hydrofluoric acid, concentrated sulfuric acid, mixtures of sulfuric and hydroiiuoricy acids, fiuorosulfonic acid,'chlorosul fonic acid, concentrated hydrofiuoric acid containing .small proportions of boron triiiuoride,

boron trii'luoride-water complexes, phosphoric acid containing dissolved boron triiiuoride, aluminum chloride-hydrocarbon complexes, and the like.- The choice of catalyst depends upon economieparaffins with olens having three or more carboni atoms per molecule, concentrated or substantially anhydrous hydrouoric acid is preferred. In some instances, as when there is a nearby market' for impure sulfuric acid, such as spent alkylation acid, it may be advantageous to use sulfuric acid as the catalyst. When ethylene and/or normal parafllns or cyclohexane are used as alkylating reactants, it is desirable to use one oi' the most active of the alkylation catalysts, such as aluminum chloride or bromide. or, preferably hydroiluoric acid containing a small proportion of boron triiluoride, such as 1 to 10 per cent.

Although ordinary mixing of any oi the abovementioned catalysts with an olenn resultsV in rapid polymerization and hydropolymerization of the olein to form products which are relatively undesirable as alkylating reactants and which destroy the activity of the catalyst for effecting alkylation, these catalysts may be brought together with oleins in such a manner that reaction is limited to formation of simple olen-catalyst addition products such as alkyl iiuorides or sul.- fates, simple aluminum chloride-olefin complexes, and the like. Also, processes have been proposed for rapidly absorbing oleflns in large quantities of catalysts, such as hydrouoric acid or sulfuric acid, and passing the resulting absorbate or extract to an alkylating zone; in these processes, the time of contact of olen with the catalyst prior to introduction into an alkylating zone must be inconveniently short, and even then some of the olen is usually lost by undesired polymerization and hydropolymerization. By following the principles of the present invention the over-all loss of olefin -by undesirable polymerization reactions can be reduced practically to nothing, and the time of contact of olefin (or oleiln-catalyst addition product) with the catalyst prior to introduction to an alkylating zone can be increased to a convenient value. l

The nature of the chemical reactions which are involved in the absorption of oleflns by an acid-type alkylation catalyst may be illustrated by the following simplified chemical equations:

CsHcA nCsHt --e (GzHum) '-i- A (complex) (propylene) (polymer) catalyst Reaction 1 represents the formation of a simple olefin-catalyst addition product. Thisreaction occurs under relatively mild conditions and is generally noncatalytic in nature. Reaction 2 occurs readily in the presence of excess of catalysts but does not occur readily in the absence of free catalyst; this reaction involves the combination of an initially formed simple olen-catalyst complex or addition product molecule with one or more molecules of -free or uncombined olen to form polymer. It is apparent from these equations that conditions favorable' to Reaction 2, namely, the presence of olefin catalyst complex, free oleiin, and excess catalyst, will exist when an olen-containing hydrocarbon stream is directly contacted with an excess oi.'y catalyst, as in ordinary alkylation or in direct oleiin-extraction processes. If, in accordance with this invention, the oleiin is contacted with Just sufficient catalyst to combine with the olefin, Reaction 1, which is noncatalytic, can occur readily, but Reaction 2, which requires excess catalyst, cannot occur readily. Then, if after the oleiin is substantially completely converted to the simple olefin-catalyst complex, as illustrated by Reaction 1 the complex is contacted with excess catalyst, as in the extracting step of this invention, Reaction 2 still asoman cannot occur readily because, although there is Reactionv 1 is reversible, the reverse reaction is excess catalyst. there is relatively little or substantially no free or uncombined clen. Although sufnciently slow that the free olen concentration and consequently the rate of polymerization by Reaction 2 is very much lower when the principles ofthis invention are followed than when the olefin is extracted directly with excess catalyst.

One aspect of this invention comprises selectively promoting specific side reactions, other than polymerization of olefins, which normally occur to only a minor extent in acid-catalyzed alkylation of paraiiins with oleflns.

One particularly noteworthy side reaction selectively promoted in accordance with the present invention results in the over-all effect of a hydrogen-transfer 4from the reactant parafiln to the oleilnic reactant, followed by juncture ofthe resulting dehydrogenated paraiin or newly formed oletln" with unreacted parailln. This reaction produces a by-product paramn having the same number of carbon atoms per molecule as the oleilnic reactant, and a product parafiln having exactly twice as many carbon atoms per molecule as the original parain in the feed. This reaction is particularly desirable when isobutane is being reacted with propylene, normal butenes, or amylenes, especially when a plentiful supply of isobutane is available, since the product parailln is mostly 2,2,i-trimethylpentane (isooctane), which is desirable because of its high octane rating.

Isobutane and propylene ordinarily yield 2,3- and 2,4-dlinethylpentanes by simple vparamnolen juncture. whereas they yield propane and octanes (mostly isooctane) by the hydrogen transfer-alkylation lust described. Isooetane has a higher octane rating (A. S. T. M. octane No. `100 than the dimethylpentanes (A. S. T. M.

octane No.=82 and 89) and the theoretical yield of isooctane based on the weight of propylene in the feed is 271 per cent, which is considerably more than the theoretical yield of dimethylpentanes of only 238 per cent. The by-product propane may be dehydrogenated in a dehydrogenation step to produce propylene and hydrogen, and the resulting propylene may be returned to the hydrogen transfer-alkylation step.

Although the mechanisms oi' all the reactions are not yet fully known,- the following illustrative chemical equations, deduced from data obtained by extensive experimentation, appear to account for some of the principal reactions of isobutane and propylene that can occur in acid-catalyzed alkylation:

Simple paran-ole/in juncture 01H10 CiHs -4 C H (isobutane) (propylene) 7 l5 (dimethylpentane) Hydrogen transfer-alkylation o CzH1A CzHe HA (propylene) (catalyst) (propyl derivative) CaHiA -l- CcHle C s (propane) (sobutyl derivative) BA CAHIA -e C El (isobutylene (catalyst) assaiso- Isobutane and normal butenes yield 2.3.4-tri-f methylpentane and 2.4-dimethylhexaneby slmple parafnnolefln juncture. whereas they yield mostly isooctane by hydrogen transfer-alkylation. Of these products isooctane `,has the highest octane number and is therefore the most desirable for use in such motor fuels as aviation gasoline. .Although the hydrogen transfer-alkylation is more desirable, in reacting isobutane and normalv `tane with amylenes yield nonanes, which have not yet been positively identified as to particular isomers. The corresponding hydrogen transferalkylation yields isooctane as a product and pentanes as a by-product. This reaction occurs to an appreciable but minor extent under ordinary alkylating conditions, but by application of this inventlon it may be selectively greatly encouraged.

The isooctane thus produced as a major product .has a higher A. S. T. M. octane number (100) than that of the nonane fraction normally produced (e. a. 91.6). Although the theoretical yield of octanes based on the weight of olefin in the feed by this hydrogen transfer-alkylation is slightly less than the theoretical yield of nonanes by ordinary alkylation, the by-product pentanes are also useful for blending in gasollneand should be included in a consideration of the relative yields Accordingly, the total theoretical yield of gasoline products (octanes plus pentanes) is 266 tion, or considerably more than that of 183 for 'the ordinary or simple-juncture alkylation.

Other examples of hydrogen transfer-alkylations are: isobutane and cycloolefins to give octanes and by-product cycloparaiilns; isobutane and ethylene yto give octanes and ethane; and the line. The reaction of isobutane and cycloolenns, such as cyclohexene, proceeds readily under about the same conditions as the reaction of isobutane and normal butenes. 'When ethylene is used, it is desirable to use a relatively high reaction temperature such as about 200 to 400 F., or a very active catalyst to obtain reasonably rapid reaction rates. One of the most satisfactory catalysts for use in alkylating with ethylene consists of substantially anhydrous hydroiiuoric acid having dissolved in it a minor proportion,

such as 1 to 10 per cent by weight, of boron fluoride; the small proportion of boron fluoride has a strong promoting or enhancing edect on the catalytic action of the hydrouoric acid, whereby ordinary temperatures, such as 100 to 200 F., maybeused. f

In the alkylation of isobutane with butylenes the over-all reaction already mentioned which may be termed olefin isomerization-alkylation tends to minimize diiferences in products obtained from different butylenes. That is, there is a tendency for any given butylene to isomerize, under alkylatlng conditions, to an equilibrium mixture of the various butylenes. If an equilibrium mixture (thermochemical equilibrium) were4 actually obtained before any of the butylenes entered into the alkylation reaction, identical products would be obtained from each of the different butylenes. Actually, although some isomerization of butylenes occurs prior to conumption of the butylenes by alkylation in ordinary acid-alkylatlon systems, the isomerization does not approach equilibrium. The products from alkylation of isobutane with rvarious butylenes, therefore, are qualitatively similar, but differ in the relative proportions of the various constituents. For example, the alkylate from butene-l contains relatively the least isooctane and the most 2,4-dimethylhexane; the alkylate from isobutylene contains the most isooctane and the least 2,4-dimethylhexane, and the alkylate from butene-2 contains intermediate proportions of isooctane and 2,4-dimethylhexane and a major proportion of 2,3,4-trimethylpentane, which is the simple orvprimary juncture product of isobutaneand butene-2. Isooctane is the principal primary juncture product of isobutane and iso- 1 butylene; 2,3,3'trimethylpentane is another'desirable primary juncture product (A. S. T. M. octanel rating=l00) of isobutane and isobutylene,

' but only small proportionsl are formed. The

weight per cent for the hydrogen transfer-alkyla principal primary juncture product of isobutane and butene-l is 2|,4-dimethylhexane; another primary juncture product of isobutane and butene-l, which is formed only in very small proportions, however, is 2-methyl-3-ethylpentane. By the application of the present invention, the isomerization of normal butylenes prior to juncture with isobutane can be encouraged to'the extent that they give products which are similar to that hitherto normally obtained only from isobutylene.

Another desirable side reaction, which maybe selectively encouragedin accordance with the principles of this invention, occurs normally only to a minor extent in the alkylatlon of isopentane with oleilns. Thisrside reaction results in an apparent disproportionation of isopent'ane to isobutaneV and isohexanes g2- and 3methylpen tanes). For example, under some conditions,

which are especially effective in the alkylation of lsopentane with olens in the presence of anhydrous hydroiluoric acid, a surprisingly large proportion of the isopentane is converted to isobutane and isohexanes, concurrently with primary alkylation of another part of it, so that yields of hexanes and higher-boiling gasoline hydrocarbons as high as 500 or more per cent by weight of the olefin in the feed are obtained. This disproportionationalkylation may be advantageously carried out in a combination alkylationfractionation equipment wherefrom isobutane is distilled overhead, in company with some hydrouoric acid, while the reactions are progressing. The isobutane produced by the disproportionation may be used as feed stock for other processes, as for s, process in which it itself is alkylatedu in the interest of an increased yield of higherboiling or gasoline hydrocarbons from the disproportionationalkylation, the isobutane is` prefer ably removed from the reaction mixture as soon as possible after formation, and it is preferably' l. Diderent'reactions have different temperature coeflicients of reaction rates, so that certain reactions may be selectively encouraged by selecting and controlling the temperature and the reactiontime. f v

2. Over-allor mass reaction rates 4are dependassmes., .A

concentratie of 'combined ,clean with minimum concentrations of free cleiln eviv dently involves Atiie direct use of alkyl ent upon concentrations of reactants. so that certain reactions may be selectively encouraged by suitably controlling concentrations of reactants.

ativelyr more than the reaction rateof primary` alkylation, and it increases the reaction rate of oleiin isomerization relatively less than the reaction rate of primary alkylation. The practical temperaturerange is. of course, limited by excessive cracking reactions or decompositions at the upper limit and by disadvantageously low reaction rates at the lower limit. 'Within the practical temperature range. the optimum temperature for favoring the desired side reaction may be readily determined by trial for any particular case. For promoting hydrogen transfer-alkylation and disproportionation-alkylation, a temperature in the upper .part of the practical range is to be preferred: for promoting olefin isomerization-falkyiation, a temperature in the lower part of thet practical range is to be preferred. The practical temperature range varies somewhat with specific catalysts and reactants, but'for the sake oi concreteness it may be said vto be roughly from about 20 F. to about 800 F. for such a catalystv as hydrogen fluoride and for oleflns other than ethylene. The reaction temperature-is interrelated with the reaction time. for the reaction time required to eifect a given extent lof reaction is generally 'shorter at a high temperature than l at a l'ow temperature.

With respect to the second of these principles.' in general, the desired side reactions are preferentially favored if the concentration of free olefin is minimized by reaction with the catalyst before the olefin can react with the paraiiln -by primaryV alkylation or with additional olen by polymerization-.2?, Although oleilns readily addl to hydrogen iiu'ori'de, or undergo hydroiluorination, to form Y alkyl-fluoridea` the part played by this reaction tures in the presence of concentrated hydroiluoric in primary paraflln-olefin and olen-,oleiin junc- 7 55 acid as a catalyst is that of a reversible side reac1 tion, not that of an intermediate reaction; that,l is, these primary juncture reactions comprise the "f additlonci' an-activated paraiiln or oleiin molecule directly to a simple olefin molecule, and alkyl fluorides or similar oleiin derivatives Vundergo these reactions only after being converted to simpie oieiix'n. Hence, the rates of primary paraffin oleiln and volefin-olen junctures are decreased by lowering the concentration of free or uncom bined olefin in the reaction zone. Conversely, the rates of the competitive side reactions, in which the oleiln appears to take partrelatively more effectively in the form of `a compound or complex with the catalyst, as illustrated by Equations 2 `to 5, -are simultaneously increased. Specific examples of such side reactions are those involving hydrogen transfers. olefin isome'rizations, and the like.

Although one excellent method ci obtaining 75 suon es any1 duendes, alcohols. and the use, :nl

stead ofoleiins; as alkylation agents, in practice this method makes necessary the use of a separate process for manufacturing such alkyl compounds `from olenns. A simple combination'process for converting oleiins to alkyl iluorides followed by an alkylating step is therefore desired for commercial lapplications. In accordance with one aspect of the present invention, results approaching the ideal are obtained by adding a limited proportion of a liquid acid-type alkylation catalystto an elena-containing hydrocarbon stream, the total added catalyst being roughly equivalent stoichiometricaliy to the total olefin, and giving the olefin and catalyst an opportunity to become combined, prior Ato introducing the stream into an alkylating zone, in which an excess of the same catalystand an excess of an alhrlatable hydrocarbon are present. One modiiication, which is especially suitable for use when the olefin-containing stream contains an excessive proportion of inert or diluent hydrocarbons, comprises-adding a limited proportion of a liquid acid-type alkylation catalyst to an olefin-containing hydrocarbon stream. the total added catalyst being .i

roughly equivalent stoichiometrically to the total oleiin, giving the olenn and catalyst an opportunity to become combined, extracting the resulting oleiin-catalyst addition'product with excess of the'same catalyst, and the resulting ex= tract to an alkylating zone in which an alkylat`l able hydrocarbon is present. ,Such a procedure'V differs from previous practice, inwhich it haarI vbeen thought desirable to avoid contacting the oleiin with the alkylating catalyst prior'to intro'" duction into the alkylating zone, in order to minimize undesired olefin consumption by polymerisation and hydropolymerization, which occur-ex- AA tensively when a separate catalyst phase is present. In accordance with the concept of this in# vention, however, in order to selectively promote desirable side reactions such as have been de-" scribed hereinbefore, it is advantageousr'to cou-y tact the olen, diluted by paramn hydrocarbons,l

with roughly an equivalent proportion of cata# lyst prior to introduction into the alkylating zone; since thereby the formation of menu-catalyst addition products may be brought about without" appreciable consumption of olefin by pcl'ymerisation, coniunct polymerization, and the l'Fur-f' ther, when the olenn is diluted by excessivlallrc portions of inert hydrocarbons," it is advntageous to extract olefin-catalyst addition in excess catalyst prior to introducing it into the alkylating -zone since thereby the' concentrationj'l of inert materials in the alkylating zone is' decreased. Once formed, these addition products apparently do not react with amnistie-'parains until they are'reconverted to oleilnajqithe'r. tile same as the original oleilns or dierent from them, thereby causing a delay in the enacting of paraii'in-oleiin iunctures and consequentlyV presenting opportunities for hydrogen transfers, oleand/or recoverable from thema The solubilityoi' hydrofluoric acid in paraillns is illustrated by;

fin isomerizations, and disproportionations to oc- As the catalyst. liquid substantially anhydrous hydroiluorie acid is Ipreferred because it is "ati-'ly vantageously appreciably soluble in hy"- drocarbons and withal it is readily removable which has'been experimentally determined to increase with temperature substantially linearly from 0.3 to 0.9y per cent by weight in the temperature range of 32 to 140 F. A concentrationA or uniformly dispersed hydrouiloric acid oi' be tween about 0.6 and 4 per cent by weight is preferred. However, the invention is generally applicable with minor modifications to 'other liquid acid-type condensation catalysts, such as sulfuric acid, mixtures of sulfuric acid and hydroiluoric acid, chlorosulionic acid, iiuorosulfonic acid, phosphoric acid, phosphoric acid-boron uoride mixtures, aluminum chloride suspended or dissolved in various solvents, 'hydro iluorlc acidv containing small proportions oi dissolved substances such as boron iluoride. and the like. Hydroiluoric acid is usually preferred in many alkylations because it results in a more clean-cut reaction and the ranges oi operating conditions used with it are generally broader and more readily controllable than with other catalysts. When ethylene and/ or normal paramns are reactants, however, it is desirable to add a small proportion, such as 1 to 10 per cent by weight, of boron fluoride to the catalyst to increase the activity of the catalyst.

Understanding of some aspects oi the invention may be aided by reference to the accompanying drawing, which is a schematic now-diagram of one arrangement oi' apparatus suitable for practicing the invention. For the sake oi' concrete illustration, the description in'connec tion with this flow-diagram will be limited kto isobutane and propylene as the alkylation reactants and to concentrated hydrouoric acid as the catalyst. The invention is applicable to many diii'erent alkylation reactants and catalysts, and,

taking into account specific characteristics of various reactants and catalysts, those skilled in the art of hydrocarbon conversion will be able to modify the flow scheme discussed herein to suit other specic instances.

A liquefied olen-containing hydrocarbon.

stream, such as one containing about 1 to 50 per cent propylene, the remainder being relatively inert hydrocarbons such as propane, athene, and normal butane, is admitted through inlet Ii to mixer l2. A proportion of concentrated liquid hydrofluoric acid roughly molecularly equivalent to the total unsaturates (propylene) is admitted through conduit I3. Very rapid dispersion of the hydrofluoric acid throughout the oleiin-contalning stream should be effected in order to avoid high local concentrations oi uncombined hydrouoric acid and to minimize the tendency for oleiln to polymerize or hydropolymerize. The

mol proportion of hydroiluoric acid used should be in the range of about 0.5 to 3 times the total f olefin. Usually a proportion between about i and 1.5 is preferable. At proportions less than 1 there is insuiiicient hydrofiuorlc acid to combine with all the olefin, whereas at proportions greater than about 1.5,` polymerization may become considerable or even excessive. The hydroiiuoric acid should be introduced at a. point of high turbulence either in the inlet conduit to mixer I2 or directly in the mixer. Mixer I2 may be any suitable means, such as a small baiiled chamber, an orificeor jet-type mixer, a centrifugal pump, or the-like, for insuring rapid dispersion oi' the hydrofluoric acid throughout the hydrocarbon stream. g

From mixer I2 the mixture passes through conduit Il to time tank Il, wherein conditions are adjusted to favor addition oi' hydroiluoric acid to l ass'mec propylene without promoting polymerization' or hydropolymerlzation ofvpropylene. vThe conditions may comprise; a. temperature inthe range of about 40 to 200 F.; a contact or reaction time,

inversely dependent on the temperature, in the range of a minute or less to an hour or more; and a pressure sumcient to maintain the mixture predominantly in the liquid phase. There should be `suiiicient agitation in time tank itlto prevent 'l formation of a separate liquid hydrofiuoric acid layer in the bottom. Normally a temperature of about B0 to 130 F. is preferred, because the tem-- perature is readily maintained within this range without the use of reirigerating or heating equipment. The corresponding time and pressure ranges are about 2 to 30 minutes, and about 100 to 300 pounds per square inch, respectively.

The resulting isopropyl uoride-containing mixture passes from time tank It through conduit it to mixer il wherein it is intimately contacted with liquid concentrated or substantially anhydrous hydroiluoric acid admitted to mixer il e through conduit it. When the proportion of inert diluents is low, it is desirable to pass part. and sometimes all, of the mixture from time tank` it through conduit itA directly to alkylator 2i. This is usually economical when the concentration oi' alkyl iluorides is above about 20 mol per cent.' The conditions in mixer I'I are selected to permit extraction of alkyl iluorides (isopropyl iluoride) by the liquid hydrofluoric acid. The volume of hydroiluoric acid used should be suiilcient to form a separate acid phase and preferably should be equivalentin mols to about 5 to 20 or more times the number oi mols of alkyl iluorides extracted. Lesser proportions are likely to result in incomplete extraction oi' alkyl fluorides, whereas greater proportions place an unnecessarily large quantity of hydroiluoric acid in circulation in the system. The time of contacting may be in the range of about 30 seconds to ilve minutes-the shorter the better as long as intimate contacting of acid and hydrocarbon is attained.

When the time is excessively long, decomposition and degradation of the alkyl iluorides occur. The temperature should be as low as is economically feasible within the range -20 to 130 F., preferably at least below F., in order to minimize the solubility of hydroiluoric acid in the hydrocarbon phase. From mixer I1 the mixture passes through conduit ItA to separator I9, wherein itis separated by cooling and/or gravitational or centrifugal means into two liquid phases. The time of residence of the hydroiiuoric acid phase in separator I9 should be as short as conveniently possible, preferably less than about 10 minutes, in order to minimize degradation reactions of the isopropyl iluoride. The allowable time is inversely dependent upon the temperature and inversely dependent upon the concentration of isopropyl iiuoride in the hydrofiuoric acid. Generally the temperature should be as low as possible within the range of about -20 to 130 F., usually at least below 100 F., depending upon the degree may be taken as a typical alkylatable hydrocarbon, is admitted to alkylator 2l `through inlet 22. Additional hydrofluoric acid may be in troduced through 23, though generally the hydrofluoric acid in the mixture from separator I9 is Sumcient. The reaction conditions in alkylator 2l, which are well-known tothose skilled in the art of hydro'iluoric acid alklation, may comprise a temperature in the range -20 to 200 F., suf- `iicient pressure to maintain liquid phase. an

average reaction time in therange of about 1 to 100 minutes, good agitation, an isobutane-to alkyl iiuoride mol ratio in the rangeV of about 1.5 to 10 or more, and a hydrocarbon-to-catalyst volume ratio in the range of about 0.2 to 4. Near optimum conditions, all things considered, are about as follows: temperature, 100 F.; pressure, 100 pounds per square inch; time 20 minutes; isobutane-to-alkyl fluoride mol ratio, 5; hydrocarbon-to-catalyst volume ratio. about l.

From alkylator 2l, the reaction mixture is passed through conduit 24 to separator 26, wherein, by cooling and/or gravitational or cen-` trifusal means, it is separated into twoliquid phases. The lighter or hydrocarbon phase from separator-'25, is` passed through conduit 28 to deisobutanizer 21, wherefrom a fraction comprising a major proportion of isobutane and a minor proportion of hydrogen fluoride is distilled overhead and is recycled via conduit 28 to alkylator 2|, and a bottom or kettle fraction, comprising normally liquid parailin hydrocarbons, is passed through conduit 23 to rerun column 30.

Rerun column 30, by fractional distillation, separates the hydrocarbons from the bottom of deisobutanizer 21 into a maiorA fraction or saturated gasoline-range hydrocarbons, principally isooctane and dimethylpentane, which may be bon conversion. For example, used hydroiiuoric acidmay be purified in a separate distilling step not shown in the drawing; additional fractionators maybe employed for purifying recycled isobutane or for separating out particular narrowboiling fractions such as isooctane from the alkylate; and in some instances it will be desirable to include a step for removing organically combined iluorine from the products. Theremoval of organic iiuorine is readily accomplished by contacting the products with a dehydrogenationtype catalytic material, such as metal-impregnated contact masses or, more economically, bauxite, at a temperature in the range of about 100 to 500 F. Conventional equipment such as pumps, valves, conduits, coolers, heaters, fractionators, and the like, are to be used wherever' they appear necessary or convenient.

To illustrate further some of the manyaspects of this invention. the following speciiic examples are given.

Example I To a refinery gas fraction comprising about 10 mol per cent propylene and 90 mol per cent propane is added in a centrifugal-type mixer a proportion of concentrated hydroiiuoric acid molecularly equivalent to the propylene. The mixture withdrawn through outlet Il, and intma minor fraction of hydrocarbonsboilingabovethe desiredgasoline range.` which may be withdrawn through outlet 32. y

The lighter or hydrocarbon layer from separator I9 is passed through conduit 33 to'frac tionator 34. From fractionator 3l a mixture of hydrogen fluoride, unextracted alkyl fluorides, and hydrocarbons is distilled overhead and is `passed through conduit to separator 3l. In

separator 36, the mixture is separated bycooling and/or gravitational or centrifugal means into twol liquid phases, of which the lighter or hydrocarbon phase lsreturned through conduit 31 as reilux Ato Vi'ractionator 34, land oi' which theheavier orhydroiiuoric acid phase is recycled to preceding .steps inthe process through conduit l Il,- part of it may be passed through conduit Il to means, not shown, for puriiicatlon. Preferably. however, to economize on equipment, this part may be passed through conduit 42 to fractionator 34, wherein it mixes with oleiin-depleted hydrocarbon containing dissolved hydrcfluoric acid from separator I9. Acid-soluble materials and hydrocarbons are withdrawn through outlet 39, and the hydroiiuoric acid, relatively free from undesired dissolved materials,` is passed overhead, is separated in separator, and is recycled to the various steps requiring fresh hydroiluoric acid. Make-up hydroiluoric acid may be introduced through inlet 43.

Numerous modifications of the foregoing flow scheme, suitable for specific applications, will be apparent to those skilled in the art 0f hydrocarpasses to a reaction vessel maintained at a temperature below about to 90 F. by cold water colis. The residence time in this vessel is about 10 to 20 minutes. 'Ihe vessel is provided with a stirrer to prevent the separation of a hydroiluoric acidlayer in the bottom. From this vessel the mixture passes to another centrifugal-type mixer into which is introduced an additional quantity oi' concentrated hydroiluoric acid approximately equal in volume to the total original propylene-containing stream. The' resulting mixture passes to a centrifugal separator, `from which the heavier or hydroiluoric acid phase-is withdrawn and passed immediately to an alkylating zone. Into the alkylating zone is introduced isobutane in a mol proportion about 5 times that of the original propylene. The alkylation temperature is about F.; the pressure, 150 pounds per square inch; and the reaction time, 10 minutes. The eiiiuent mixture from the alkylating zone is separated into an acid layer which is recycled to the two mixers mentioned hereinbefore, and a hydrocarbon phase which is further separated by fractional distillation into an isobutane fraction, a motor-fuel fraction, 4and a minor4 high; boiling kettle fraction. The motor-fuel fraction It is noteworthy that the maior constituent of the alkylate is isooctane. It is noteworthy also that the octane number oi thealkylate is 93, which is considerably higher than the octane numbers of about 88 to 90 usually obtained in conventional processes for alkylatingl isobutane with propylene.

Example Il Normal butane is catalytically. dehydrogenated to the extent of about 20 to 30 per'cent, as by a catalyst comprising chromium oxide under suit- .able dehydrogenation conditions, in a manner well known to the art. To the resulting muent is added hydroiiuoric acid in a proportion approximately 1.2 times that molecularly equivalent to the butylene content. After a reaction period .of about to l5 minutes, `an excess of about 10 times as much additional liquid hydroiiuoric acid is intimately mixed with the reaction mixture, and the resulting two-liquid-phase mixture is aliowed to settle into two layers. The lower layer is passed to an allryiation zone wherein itis intimately agitated with an approximately equal voie urne ot? liquid isopentane `at about 100 F. for about 10 to' l5 minutes. The resulting mixture is then separated into two liquid layers, and the lower layer is recycled and/or purified. The upper layer is freed from acid and is then fractionaily distilled to isolate the gasoline-range product boiling above pentane. This product amounts to about 400 to 450 per cent -by weight of the butylene, and it comprises about 40 to d5 per cent isoliexanes; its octane number is about d0. in addition to this gasoline-range product, there is formed isobutane in a proportion approximately molecularly equivalent to the isohexanes; this formation of isobutane is particularly desirable because the isobutane is advantageously utilizable for the production oi isooctane by alkylation with oleins.

This invention may be applied to many diHerent aikylations, including the alkylation oi. any alkylatable hydrocarbon with an oleiinlor a dioleiln having 2 to l2, preferably 3 to 5, carbon atoms per molecule in the presence of a suitable liquid acid-type alkylation catalyst. Alkylatable hydrocarbons, as now known, include aromtics, isoparamns, normal paralns, and cycloparailns. In all such alkylations this invention provides a simple, economical method for efciently concentrating, and utilizing as alkylating agents, oleiins which are accompanied by undesirable proportions of inert or diluent hydrocarbons.

This invention is of great value in instances in which it is desired to promote certain desirable reactions, such as hydrogen transfer-alkylation, oleiln isomerization-alkylatlon, and disproportionation-alkylatlon, preferentially-to simple ory therein, but it should be restricted only in accordance with the appended claims. i

Iclaim:

1. A process for reacting propylene and isobu- `tane to produce propane and octanes as major products, which comprises intimately admlxing a liquid hydrocarbon material comprising propylene with liquid hydroiluoric acid in an amount substantially equimolar to the propylene at a temperature between about 40 and 200 F. for a peing isobutane with said nquid hydronuoric scid phase at a reaction temperature not less than about F. forr a reaction period such that prof pane and octanes are'produced, and separating from eiliuents ci' said reaction a hydrocarbon `fraction comprising octanes so produced.

2. A process for reacting a low-boiling normal olefin and a low-boiling isoparamn to produce a low-boiling normal paraiiln corresponding to said normal olefin and higher-boiling isoparaiilns as major products, which comprises intimately adintimately admixing with the resulting material,

an excess oi liquid hydroiiuoric acid at an extraction temperature not greater than about 100 F'. and subsequently separating from residual hydrocarbons a resulting liquid hydrofiuoric acid phase, admixlng a low-boiling isoparamn with said liquid hydroluoric acid phase at a reaction temperature not less than about 100 F. for a reaction period such that low-boiling normal parafns corresponding to said normal olens and isoparaiilns higher-boiling than said isoparamn reactants are produced, and separating from effluents of said reaction a hydrocarbon fraction comprising `high-- er-boiling isoparamns so produced.

3. An improved process for reacting a low-boiling olefin and a low-boiling isopara to produce higher-boiling paramns in the presence of a hydroiluoride acid catalyst, which comprises intimately admixing a hydrocarbon material containing a low-boiling olefin with liquid hydro iluoric acid in an amount substantially equimolar to said olefin, maintaining said admixture for not more than about 30 minutes, intimately admixing with the resulting material a substantial excess of liquid concentrated hydrofiuoric acid in an extraction step at an extraction temperature not greater than about 100 F. and subsequently separating a rst hydrocarbon phase and a ilrst liquid hydroiluoric acid phase, intimately admlxing a low-boiling isoparailln with said liquid hydrofluoric acid phase under reaction conditions such f as to produce higher-boiling parailin hydrocarbons. separating effluents of said reaction into a. second hydrocarbon phase'and a second liquid hydrofluoric acid phase, recovering a hydrocarbon product from said second hydrocarbon phase, passing a major portion of said second acid phase to said extraction step as a part of said extraction liquid,v passing said first hydrocarbon phase to a distillation step for recovery of dissolved hydrogen fluoride therefrom, passing a. vminor portion of said second acid phase to said distillation step for removal of organic impurities, and recovering from said distillation step puried hydrogen fluoride and passing same to said extraction step.

4. An improved process for reacting propylene and isobutane to produce higher-boiling parains including octanes in the presence of a hydroiluoric acid catalyst, which comprises intimately admlxing a hydrocarbon material containing propylene with liquid hydrofiuoric acid in an amount substantially equimolar to said propylene, maintaining said admixture for not more than about 30 minutes, intimately admixing with the resulting material a substantial excess of liquid concentrated hydroiluoric acid in an extraction step at an extraction temperature not greater than about 100 F. and subsequently separating a ilrst hydrocarbon phase and a ilrst liquid hydroiluoric acid phase, intimately admixing isobutane 8 nemica j extraction liquid, passing said nrst' hydrocarbon i with said liquid hydrofiuoric acid phase under reaction conditions such as to produce higher-buiiing paramn hydrocarbons including octanes, separating eiiiuents oi' said reaction into a second hydrocarbon phase and a second liquid iiydrofiuoric acid phase, recovering a hydrocarbon' product comprising octanes from said second hydrocarbon phase, passing a major portion of said second acid phase to said extraction step as a part of said phase to a distillation step for recovery of dissolved hydrozen uoride therefrom-passing a minor portion o! said second acid phase to said distillation step for removal of organic impurities,

and recovering from said distillation step purified hydmsen fluoride and passingsame to said ex` traction step. x

- MARYAN P. MAIIUSZAK. 

